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Hey guys. I've got a very thin and fragile helmet that I'm painting and I'm wondering about ways to thicken it up on the inside and strengthen it. I've used some Bondo to fix some flaws in the surface, but the stuff hardens too fast and it's too thick and heavy to be able to smear it evenly on the inside. I guess adding some fiberglass fibers and resin or epoxy might be the solution. But I need advice about what brands, kinds, or techniques would work for this. The epoxy would have to be pretty thin to spread out evenly. Thanks.

I used bondo fiberglass kit on the inside of my Sgt. Fang helmet. Worked good really made it stronger! Just go to any autoparts store (or walmart) and get the kit. Mix it and cut the fiberglass into strips (3 - 4 inches long) and then follow the directions on the package. Oh also, work fast. That stuff hardens quick.

I used bondo fiberglass kit on the inside of my Sgt. Fang helmet. Worked good really made it stronger! Just go to any autoparts store (or walmart) and get the kit. Mix it and cut the fiberglass into strips (3 - 4 inches long) and then follow the directions on the package. Oh also, work fast. That stuff hardens quick.

Yep, what tripleD said. Its common to reinforce resin helmets with fiberglass on the inside, works a treat!

Do what TrplD said , then once it is dry use a course sand paper over the dryed FGtaske of any sharp barps that have occoured as a result of the drying FG matting then after sanding mix up some of the resin with the hardener, and brush on the resin over the dryed FG this will get a nicer smoother surface you may need to repeate a few times but it willl be worth it

also FG resin will work best in warm weather if it is cold dont bother unless you can put a heater near it, and add more hardner than is recomemnded

Oh yeah! I forgot about that part. Do what BGHunter said. After you put this first coat in and let it dry/harden sand it down. I used a dremel with a sanding drum on it to get most of it. (Let me tell you the fiberglass is like shark teeth once it is done). Ouch. So sand those down and the use the sand paper to run over the whole interior of the helmet. Then just mix up some more of the resin (without the fiberglass) and put another coat on (paint brush worked good). Then sand it again with just sand paper to get out the sharp edges. Mine turned out pretty good.

Thanks guys. I've used some Bondo on it, but I must be mixing it with too much catalyst because the end result is really thick--too thick to brush or even smear on--and it hardens beyond usability in just a few minutes. I think if I had something that would poor and run in there like syrup it would be a lot easier.